Light assembly for a projector

ABSTRACT

In one aspect, a light assembly configured to be installed in a movie theatre projector includes an emitter housing with an LED emitter plate that emits a beam of light and a lens assembly. The light assembly also includes a cooling assembly configured to dissipate heat from the LED emitter plate. The a cooling assembly includes a cooling fluid jacket coupled to the LED emitter plate, where the cooling fluid jacket comprises a metal layer enclosing a hollow path for cooling fluid, and where the cooling fluid jacket is configured to allow the cooling fluid to pass through cooling fluid jacket, thereby drawing heat from the LED emitter plate. The light assembly also includes a heat sink and a cooling fan. The cooling assembly further includes cooling sections to cool the cooling fluid that flows out of the cooling fluid jacket.

RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/747,166, filed Jan. 20, 2020, which is a continuation of U.S.application Ser. No. 16/550,573, filed Aug. 26, 2019, now U.S. Pat. No.10,539,861, which is a continuation of U.S. application Ser. No.16/298,239, filed Mar. 11, 2019, now U.S. Pat. No. 10,394,111, which isa continuation of U.S. application Ser. No. 16/130,305, filed Sep. 13,2018, now U.S. Pat. No. 10,228,612, which is a continuation of U.S.application Ser. No. 15/941,583, filed Mar. 30, 2018, now U.S. Pat. No.10,088,741, which is a continuation of U.S. application Ser. No.15/467,712, filed Mar. 23, 2017, now U.S. Pat. No. 9,952,490, whichclaims priority from U.S. Provisional Appl. No. 62/312,101, filed Mar.23, 2016, the contents of which are incorporated herein in theirentireties.

TECHNICAL FIELD

The present disclosure generally relates to lighting fixtures forprojectors. More specifically, the present disclosure relates tolighting assemblies incorporating light-emitting diodes (LEDs)configured to retrofit to lighting fixtures previously incorporatingincandescent lamps.

BACKGROUND

Theatre, architectural and television projectors project high-intensitybeams of light. Currently, two primary types of basic projectors areAnalog Film Projectors and Digital Projectors. Both types of projectorsutilize very high quality incandescent or High-Intensity Discharge (HID)bulbs to create very intense light to illuminate the film or digitaldisplay and focus this display at a distance onto a movie screen.

However, these bulbs are very expensive and have a relatively shortlifespan. Currently, many projectors use a Xenon-Plasma HID bulb ratedat 3,000-5,000 watts to produce between 20,000 to 34,000 lumens (6-7LPW). The average lifetime for these types of bulbs is from 6 to 16weeks. This increases the cost of operation. These types of bulbs alsoproduce an excess amount of heat. Therefore, a high-performance coolingfan and sometimes a secondary roof mounted ventilation fan system isutilized to cool the projector. Further, the projection room requiresauxiliary air conditioning to keep temperatures at an acceptable level.

Moreover, plasma HID bulbs contain hazardous material, such as mercury.These bulbs are prone to explode. When they explode, they also damagethe projector. In fact, they are so volatile that they are shipped andstored in explosion-proof containment units to prevent bodily harm.

Accordingly, there is a need for an efficient, effective and safealternative to the bulbs currently used in projectors.

SUMMARY

Embodiments of the present invention provide a light assembly configuredto be installed in a high-lumen, high-wattage movie theatre projector.

According to some embodiments, a light assembly configured to beinstalled in a movie theatre projector includes an adaptor configured tomechanically couple to a bulb mount of the movie theatre projector andan emitter housing that comprises an LED emitter plate. At least one LEDis directly or indirectly attached to the LED emitter plate andconfigured to emit a beam of light. The lighting assembly includes acooling assembly configured to dissipate heat from the LED emitter plateand a lens assembly configured to adjust the size or pitch of the beam.The lens assembly includes a concave adjustor with a concave lensconfigured to spread the beam emitted from the at least one LED and aconvex adjustor with a convex lens configured to collimate lightreceived from the concave lens. The concave adjustor is movably attachedto the emitter housing and the convex adjustor, and the lens assembly isconfigured to be manipulated to adjust a distance between the concavelens and the convex lens, thereby adjusting the size or pitch of thebeam. The beam may be a quadrilateral-like shape, such as a square.

According to some embodiments, a lens assembly is configured to bemovably attached to an LED emitter that includes at least one LED. Thelens assembly includes a concave adjustor with a concave lens configuredto spread a beam of light emitted from the at least one LED and a convexadjustor with a convex lens configured to collimate light received fromthe concave lens. The concave adjustor is movably attached to the LEDemitter and the convex adjustor, and the lens assembly is configured tobe manipulated to adjust a distance between the concave lens and theconvex lens, thereby adjusting the size or pitch of the beam.

According to some embodiments, a light assembly configured to beinstalled in a movie theatre projector includes an adaptor configured tomechanically couple to a bulb mount of the movie theatre projector andan LED emitter comprising at least one LED configured to emit a beam oflight. The light assembly also includes a lens assembly configured toadjust a distance between a concave lens and a convex lens through whichthe beam passes. The concave adjustor is movably attached to the LEDemitter and the convex adjustor. The lens assembly is configured to bemanipulated to adjust a distance between the concave lens and the convexlens.

According to some embodiments, a light assembly system configured to beinstalled in a movie theatre projector includes a light assembly, whichincludes an adaptor configured to mechanically couple to a bulb mount ofthe movie theatre projector, a primary LED Emitter mounting plate, atleast one LED directly or indirectly attached to the primary LED Emittermounting plate, a cooling assembly configured to dissipate heat from theprimary LED Emitter mounting plate and a lens configured to collimatelight emitted from the at least one LED. The light assembly system alsoincludes a light assembly control system, separate from an existingcontrol system of the movie theatre projector, that is configured tocontrol operation of the light assembly.

The light assembly control system may be a standalone system external tothe light assembly and comprises a driver to power the at least one LED.The light assembly control system may be configured to interface withthe existing control system of the movie theater projector with regardto when the light assembly is to operate.

According to some embodiments, a light assembly system configured to beinstalled in a movie theatre projector includes a light assembly, whichincludes an adaptor configured to mechanically couple to a bulb mount ofthe movie theatre projector, a primary LED Emitter mounting plate, atleast one LED directly or indirectly attached to the primary LED Emittermounting plate, a cooling assembly configured to dissipate heat from theprimary LED Emitter mounting plate and a lens configured to collimatelight emitted from the at least one LED. The light assembly systemincludes a light assembly control system configured to control operationof the light assembly and the movie theatre projector.

According to some embodiments, a light assembly in a movie theatreprojector includes an adaptor configured to mechanically couple to abulb mount of the movie theatre projector, at least one LED attached toa primary LED Emitter mounting plate, a cooling assembly configured todissipate heat from the primary LED Emitter mounting plate, and a lensconfigured to collimate light emitted from the at least one LED. Amethod for installation of the light assembly includes placing the lightassembly control system in or proximate to the movie theatre projector,where the light assembly control system is separate from an existingcontrol system of the movie theatre projector and configured to controloperation of the light assembly. The method also includes inserting thelight assembly into the movie theatre projector by mechanically couplingthe adaptor to the bulb mount and electrically coupling the lightassembly to the light assembly control system. The method furtherincludes establishing a communication link between the light assemblycontrol system and the existing control system of the movie theatreprojector.

According to some embodiments, a light assembly configured to beinstalled in a movie theatre projector includes an adaptor configured tomechanically couple to a bulb mount of the movie theatre projector, aprimary LED Emitter mounting plate and at least one LED directly orindirectly attached to the primary LED Emitter mounting plate. The lightassembly also includes a heat sink configured to dissipate heat from theprimary LED Emitter mounting plate and a cooling fan configured togenerate airflow across the heat sink. The light assembly furtherincludes a lens mounting plate and a lens configured to collimate lightemitted from the at least one LED, where the lens is disposed over thelens mounting plate. The light assembly includes an attachment assemblyconfigured to attach the lens mounting plate to the primary LED Emittermounting plate.

The attachment assembly may include a plurality of lens mount standoffsthat attach the lens mounting plate to the primary LED Emitter mountingplate so as to maintain a predetermined distance between the at leastone LED and the lens. In other embodiments, the attachment assembly maybe configured to be manipulated to adjust a distance between the atleast one LED and the lens.

According to some embodiments, a light assembly configured to beinstalled in a movie theatre projector includes an adaptor configured tomechanically couple to a bulb mount of the movie theatre projector at afirst end of the adaptor, a primary LED Emitter mounting plate and atleast one LED directly or indirectly attached to the primary LED Emittermounting plate. The light assembly also includes a heat sink configuredto dissipate heat from the primary LED Emitter mounting plate and acooling fan configured to generate airflow past the heat sink. Theadaptor includes an elongated portion extending from the first end ofthe adaptor towards the primary LED Emitter mounting plate, where theadaptor is configured to be manipulated to adjust a length of theelongated portion so as to adjust a location of the primary LED Emittermounting plate in relation to a projector lens aperture.

According to some embodiments, a light assembly is configured to beinstalled in a movie theatre projector, the light assembly includes anadaptor configured to mechanically couple to a bulb mount of the movietheatre projector, a primary LED Emitter mounting plate and at least oneLED directly or indirectly attached to the primary LED Emitter mountingplate. The light assembly also includes a cooling assembly configured todissipate heat from the primary LED Emitter mounting plate and a lensconfigured to collimate light emitted from the at least one LED. Thecooling assembly may include a heat sink configured to dissipate heatfrom the primary LED Emitter mounting plate, a cooling fan configured togenerate airflow past the heat sink and/or one or more thermal pads incontact with the primary LED Emitter mounting plate.

According to some embodiments, a light assembly configured to beinstalled in a movie theatre projector includes an adaptor configured tomechanically couple to a bulb mount of the movie theatre projector, aprimary LED Emitter mounting plate and at least one LED directly orindirectly attached to the primary LED Emitter mounting plate. The lightassembly also includes a heat sink configured to dissipate heat from theprimary LED Emitter mounting plate, a cooling fan configured to generateairflow across the heat sink, a lens mounting plate and a lensconfigured to collimate light emitted from the at least one LED, wherethe lens is disposed over the lens mounting plate. The light assemblyfurther includes an attachment assembly configured to attach the lensmounting plate to the primary LED Emitter mounting plate.

The attachment assembly may include a plurality of lens mount standoffsthat attach the lens mounting plate to the primary LED Emitter mountingplate so as to maintain a predetermined distance between the at leastone LED and the lens. The attachment assembly may be configured to bemanipulated to adjust a distance between the at least one LED and thelens. For example, the attachment assembly may be configured to adjustthe distance between the at least one LED and the lens in response to arotation of the attachment assembly or a portion of the attachmentassembly.

According to some embodiments, a light assembly configured to beinstalled in a movie theatre projector includes an adaptor configured tomechanically couple to a bulb mount of the movie theatre projector at afirst end of the adaptor, a primary LED Emitter mounting plate and atleast one LED directly or indirectly attached to the primary LED Emittermounting plate. The light assembly also includes a heat sink configuredto dissipate heat from the primary LED Emitter mounting plate and acooling fan configured to generate airflow past the heat sink. Theadaptor includes an elongated portion extending from the first end ofthe adaptor towards the primary LED Emitter mounting plate, where theadaptor is configured to be manipulated to adjust a length of theelongated portion so as to adjust a location of the primary LED Emittermounting plate in relation to a projector lens aperture. The adaptor maybe configured to adjust the length of the elongated portion in responseto a rotation of the adaptor or the elongated portion.

According to some embodiments, a light assembly configured to beinstalled in a movie theatre projector includes an adaptor configured tomechanically couple to a bulb mount of the movie theatre projector, aprimary LED Emitter mounting plate and at least one LED directly orindirectly attached to the primary LED Emitter mounting plate. The lightassembly may include a cooling assembly configured to dissipate heatfrom the primary LED Emitter mounting plate and a lens configured tocollimate light emitted from the at least one LED. The cooling assemblymay include a heat sink configured to dissipate heat from the primaryLED Emitter mounting plate, a cooling fan configured to generate airflowpast the heat sink and/or one or more thermal pads in contact with theprimary LED Emitter mounting plate.

In one embodiment, the light assembly includes an adaptor configured tomechanically couple with a bulb mount of the movie theatre projector.The light assembly further includes a female socket rigidly connected tothe adaptor and a male socket configured to mate with the female socket.Moreover, the light assembly includes one more cooling fans configuredto generate airflow, where the one more cooling fans are attachable tothe male socket using a first attaching means. Yet further, the lightassembly includes a heat sink configured to dissipate heat, where theheat sink is attachable to the one more cooling fans using the firstattaching means; a first thermal transfer pad configured to conductheat, where the first thermal transfer pad is attachable to the heatsink using a second attaching means; a primary mounting plate configuredto be attached to the first thermal transfer pad using the secondattaching means; and a second thermal transfer pad configured to conductheat, where the second thermal transfer pad is attachable to the primarymounting plate using the second attaching means. Moreover, the lightassembly includes a board configured to be attached to the secondthermal transfer pad using the second attaching means, where an LEDArray is configured to generate light, where the LED Array is mounted onthe board. Technologies such as Surface-Mounted Device (SMD) and Chip onBoard (COB) may be used for the LED Array. Further, the light assemblyincludes a lens mounting plate configured to be attached to the primarymounting plate using a third attaching means, where the lens mountingplate is transparent to the light emitted by the LED Array; multiplelens mount standoffs configured to maintain a predetermined distancebetween the lens mounting plate and the primary mounting plate when thelens mounting plate is attached to the primary mounting plate; a lensconfigured to collimate light emitted from the LED Array, where the lensis disposed over the lens mounting plate; and a lens retainer configuredto be attached to the lens mounting plate using a fourth attachingmeans, where attaching the lens retainer to the lens mounting platesecures a placement of the lens on the lens mounting plate.

In another embodiment of a light assembly configured to be installed ina movie theatre projector, the light assembly includes an adaptorconfigured to mechanically couple with a bulb mount of the movie theatreprojector. The light assembly further includes one or more cooling fansconfigured to generate airflow, where the one or more cooling fans areattachable to the adaptor using a first attaching means. Further, thelight assembly includes a heat sink configured to dissipate heat, wherethe heat sink is attachable to the one more cooling fans using the firstattaching means. The light assembly also includes a first thermaltransfer pad configured to conduct heat, where the first thermaltransfer pad is attachable to the heat sink using a second attachingmeans. The light assembly further includes a primary mounting plateconfigured to be attached to the first thermal transfer pad using thesecond attaching means. Further, a second thermal transfer padconfigured to conduct heat, where the second thermal transfer pad isattachable to the primary mounting plate using the second attachingmeans. Yet further, a board is configured to be attached to the secondthermal transfer pad using the second attaching means. Multiple LEDs areconfigured to generate light, where the LED Array is mounted on theboard. Moreover, a lens mounting plate is configured to be attached tothe primary mounting plate using a third attaching means, where the lensmounting plate is transparent to the light emitted by the LED Array. Thelight assembly further includes multiple lens mount standoffs configuredto maintain a predetermined distance between the lens mounting plate andthe primary mounting plate when the lens mounting plate is attached tothe primary mounting plate. Moreover, a lens is configured to collimatelight emitted from the LED Array, where the lens is disposed over thelens mounting plate. Yet further, a lens retainer is configured to beattached to the lens mounting plate using a fourth attaching means,wherein attaching the lens retainer to the lens mounting plate secures aplacement of the lens on the lens mounting plate.

In another embodiment of a light assembly configured to be installed ina movie theatre projector, the light assembly includes an adaptorconfigured to mechanically couple with a bulb mount of the movie theatreprojector. Further, the light assembly includes one or more cooling fansconfigured to generate airflow, where the one or more cooling fans areattachable to the adaptor using a first attaching means. Moreover, thelight assembly includes a heat sink configured to dissipate heat, wherethe heat sink is attachable to the one or more cooling fans using thefirst attaching means. Further, the light assembly includes a firstthermal transfer pad configured to conduct heat, where the first thermaltransfer pad is attachable to the heat sink using a second attachingmeans. Yet further, the light assembly includes a primary mounting plateconfigured to be attached to the first thermal transfer pad using thesecond attaching means. Moreover, the light assembly includes a secondthermal transfer pad configured to conduct heat, where the secondthermal transfer pad is attachable to the primary mounting plate usingthe second attaching means. Further, the light assembly includes a boardconfigured to be attached to the second thermal transfer pad using thesecond attaching means. Yet further, the light assembly includesmultiple LEDs configured to generate light, where the LED Array ismounted on the board. Moreover, the light assembly includes a shroudconfigured to collimate light generated by the multiple LEDs onto aprojector lens comprised in the movie theatre projector, where theshroud is configured to be attached to the board.

Embodiments of the light assembly have a longer lifespan, which reducesthe cost of operation and makes the operation safer. Further, the LEDscontain no harmful materials and they pose no explosion hazard.Moreover, with the introduction of LED industrial lighting, there is anopportunity to utilize this ever-progressing technology for more andmore lighting opportunities. Until recently, an endeavor such as thiswas not possible due to the intense amount of illumination required to“throw” the images of a theater projector for such a long distance. Withthe advent of new Chips on Board (COB) array emitters and Surface MountDevice (SMD) arrays with unprecedented efficiencies, it is now possibleto create and maintain these high light outputs necessary for suchutilization.

According to some embodiments, a light assembly configured to beinstalled in a movie theatre projector includes an adaptor configured tomechanically couple to a bulb mount of the movie theatre projector, anemitter housing that comprises an LED emitter plate, at least one LEDdirectly or indirectly attached to the LED emitter plate and configuredto emit a beam of light, and a lens assembly configured to collimatelight emitted from the at least one LED. The light assembly alsoincludes a cooling assembly configured to dissipate heat from the LEDemitter plate, where the cooling assembly comprises a first coolingfluid jacket coupled to the LED emitter plate, where the first coolingfluid jacket comprises a metal layer enclosing a hollow path for coolingfluid, and where the first cooling fluid jacket is configured to allowthe cooling fluid to pass into the first cooling fluid jacket, along thepath and out of the first cooling fluid jacket, thereby drawing heatfrom the LED emitter plate. The cooling assembly also includes a firstheat sink coupled to the first cooling fluid jacket and a first coolingfan configured to pass air over the first heat sink. The coolingassembly may also include cooling sections that receive and cool theheated cooling fluid.

The foregoing objects and advantages of the invention are illustrativeof those that can be achieved by the various exemplary embodiments andare not intended to be exhaustive or limiting of the possible advantageswhich can be realized. Thus, these and other objects and advantages ofthe various exemplary embodiments will be apparent from the descriptionherein or can be learned from practicing the various exemplaryembodiments, both as embodied herein or as modified in view of anyvariation which may be apparent to those skilled in the art.Accordingly, the present invention resides in the novel methods,arrangements, combinations, and improvements herein shown and describedin various exemplary embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a projector bulb in a light assemblyused in theatres, according to prior art.

FIG. 2 shows an exploded view of a light assembly configured to beinstalled in a movie theatre projector, in accordance with variousembodiments disclosed herein.

FIG. 3 shows a cross-section view of the light assembly of FIG. 2 afterassembly.

FIG. 4 shows a perspective view of one end of the light assembly of FIG.2 installed in a movie theatre projector.

FIG. 5 shows a perspective view of a light assembly configured to beinstalled in a movie theatre projector, in accordance with someembodiments.

FIG. 6 shows a perspective view of the light assembly of FIG. 5.

FIG. 7 shows a perspective view of a light assembly retrofitted in amovie theatre projector, in accordance with some embodiments.

FIGS. 8A-8B show perspective views of a light assembly retrofitted in amovie theatre projector and including an attachment assembly, inaccordance with some embodiments.

FIGS. 9A-9B show a perspective views of a light assembly retrofitted ina movie theatre projector with an adjustable adaptor, in accordance withsome embodiments.

FIG. 10 shows a diagram of an existing movie theatre projector.

FIG. 11 shows a diagram of a light assembly system installed in themovie theatre projector with a standalone light assembly control system,according to some embodiments.

FIG. 12 shows a diagram of the light assembly system in the movietheatre projector with air ventilation components, according to someembodiments.

FIG. 13 is a flowchart showing a method of installing the standalonelight assembly control system, according to some embodiments.

FIG. 14 shows a perspective view of a light assembly retrofitted in amovie theatre projector and including an attachment assembly with threetiers, in accordance with some embodiments.

FIG. 15 shows an exploded view of the light assembly of FIG. 14, inaccordance with some embodiments.

FIGS. 16A-16C illustrate an adjustment of the distance between a concavelens and a convex lens, according to some embodiments.

FIGS. 17A-17C illustrate a cooling assembly, according to someembodiments.

FIGS. 18A-18B illustrate a light assembly that houses the coolingassembly portion shown in FIG. 17A, according to some embodiments.

FIG. 19 illustrates an example internal design of a water jacket,according to some embodiments.

DETAILED DESCRIPTION

All descriptions are for the purpose of showing selected versions of thepresent invention and are not intended to limit the scope of the presentinvention. Non-limiting and non-exhaustive embodiments of the presentinvention are described with reference to the preceding figures, whereinlike reference numerals refer to like parts throughout the various viewsunless otherwise precisely specified.

The present disclosure relates to a light assembly configured to beinstalled in a movie theatre projector. The light assembly is configuredto replace one or both of an arc discharge lamp and an incandescentlamp. The light assembly includes an adaptor configured to mechanicallycouple with a bulb mount of the movie theatre projector. The adaptor mayinclude a cylindrical extension, where an external surface of thecylindrical extension includes screw threading configured to mate with acomplimentary screw threading comprised in an internal surface of thebulb mount. Further, the adaptor may be configured to receive electricalpower from the bulb mount when the adaptor is mechanically coupled tothe bulb mount. The bulb mount may correspond to one of an anode and acathode.

The light assembly further includes a female socket rigidly connected tothe adaptor and a male socket configured to mate with the female socket.Moreover, the light assembly includes one or more cooling fansconfigured to generate airflow, where the cooling fans are attachable tothe male socket using a first attaching means. The cooling fans mayinclude multiple cooling fans configured to be attached to each other oron other areas of the light assembly heat sink using the first attachingmeans.

Each of the multiple cooling fans may be configured to be simultaneouslyoperational. Further, one or more of the multiple cooling fans may beconfigured to be activated based on failure of one or more other coolingfans of the multiple cooling fans. Accordingly, the light assembly mayinclude a failure indicator device configured to indicate failure of acooling fan. Yet further, the light assembly includes a heat sinkconfigured to dissipate heat, where the heat sink is attachable to theone or more cooling fans using the first attaching means; a firstthermal transfer pad configured to conduct heat, where the first thermaltransfer pad is attachable to the heat sink using a second attachingmeans; a primary mounting plate configured to be attached to the firstthermal transfer pad using the second attaching means; and a secondthermal transfer pad configured to conduct heat, where the secondthermal transfer pad is attachable to the primary mounting plate usingthe second attaching means. The light assembly may also include a socketadaptor plate disposed between the male socket and the heat sink, wherethe socket adaptor plate may be configured to be attached to each of themale socket and the heat sink using the first attaching means. Further,the light assembly may include multiple spacers disposed between thesocket adaptor plate and the heat sink, where the multiple spacers maybe configured to maintain a predetermined distance between the socketadaptor plate and the heat sink when the socket adaptor plate isattached to the heat sink using the first attaching means.

Moreover, the light assembly includes a board configured to be attachedto the second thermal transfer pad using the second attaching means,where an LED Array is configured to generate light, where the LED Arrayis mounted on the board. The LED array comprises a plurality of LEDs.Technologies such as Surface-Mounted Device (SMD) and Chip on Board(COB) may be used for the LED Array and the board. The primary mountingplate with the LEDs may be considered to be a primary LED Emittermounting plate.

Further, the light assembly includes a lens mounting plate configured tobe attached to the primary mounting plate using a third attaching means,where the lens mounting plate is transparent to the light emitted by theLED Array. The light assembly may include multiple lens mount standoffsconfigured to maintain a predetermined distance between the lensmounting plate and the primary mounting plate when the lens mountingplate is attached to the primary mounting plate. These lens mountstandoffs may be considered to be part of an attachment assembly. Thelight assembly may also include a lens configured to collimate lightemitted from the LED Array, where the lens is disposed over the lensmounting plate, and a lens retainer configured to be attached to thelens mounting plate using a fourth attaching means, where attaching thelens retainer to the lens mounting plate secures a placement of the lenson the lens mounting plate.

According to further aspects, the light assembly may include an AC-DCconverter configured to convert alternating current to direct current,where the AC-DC converter may be configured to provide power to the LEDArray. Further, the AC-DC converter may include a power adjusterconfigured to adjust a power level supplied to the LED Array. Also, theAC-DC converter may be electrically connected to the adaptor, where theadaptor is configured to receive electrical power from the bulb mount.Moreover, the AC-DC converter is configured to be attached to the lightassembly by using a fifth attaching means.

According to further aspects, the light assembly may include a shroudconfigured to collimate light generated by the LED Array onto aprojector lens comprised in the movie theatre projector. Further, thelight assembly may include an adjustment rod configured to adjust analignment of the light assembly in relation to the projector lens, wherea foot portion of the adjustment rod may be configured to be immovablymounted on a base of the movie theatre projector, wherein a head portionof the adjustment rod may be movably attachable to the shroud.

According to further aspects, the adaptor may be further configured toform a tight contact with an interior surface of a projector shroudcomprised in the movie projector, where the tight contact directs airflow for cooling, where the light assembly may be configured to bedisposed within an interior volume of the projector shroud.

According to some aspects, a light assembly configured to be installedin a movie projector is disclosed. The light assembly includes anadaptor configured to mechanically couple with a bulb mount of the movietheatre projector. The light assembly further includes one or morecooling fans configured to generate airflow, where the one or morecooling fans are attachable to the adaptor using a first attachingmeans. Further, the light assembly includes a heat sink configured todissipate heat, where the heat sink is attachable to the one or morecooling fans using the first attaching means. The light assembly alsoincludes a first thermal transfer pad configured to conduct heat, wherethe first thermal transfer pad is attachable to the heat sink using asecond attaching means. The light assembly further includes a primarymounting plate configured to be attached to the first thermal transferpad using the second attaching means. Further, a second thermal transferpad is configured to conduct heat, where the second thermal transfer padis attachable to the primary mounting plate using the second attachingmeans. Yet further, a board is configured to be attached to the secondthermal transfer pad using the second attaching means. Multiple LEDs areconfigured to generate light, where the LED Array is mounted on theboard. Moreover, a lens mounting plate is configured to be attached tothe primary mounting plate using a third attaching means, where the lensmounting plate is transparent to the light emitted by the LED Array. Thelight assembly further includes multiple lens mount standoffs configuredto maintain a predetermined distance between the lens mounting plate andthe primary mounting plate when the lens mounting plate is attached tothe primary mounting plate. Moreover, a lens is configured to collimatelight emitted from the LED Array, where the lens is disposed over thelens mounting plate. Yet further, a lens retainer is configured to beattached to the lens mounting plate using a fourth attaching means,where attaching the lens retainer to the lens mounting plate secures aplacement of the lens on the lens mounting plate.

According to some aspects, a light assembly configured to be installedin a movie theatre projector includes an adaptor configured tomechanically couple with a bulb mount of the movie projector. Further,the light assembly includes one or more cooling fans configured togenerate airflow, where the one or more cooling fans are attachable tothe adaptor using a first attaching means. Moreover, the light assemblyincludes a heat sink configured to dissipate heat, where the heat sinkis attachable to the one or more cooling fans using the first attachingmeans. Further, the light assembly includes a first thermal transfer padconfigured to conduct heat, where the first thermal transfer pad isattachable to the heat sink using a second attaching means. Yet further,the light assembly includes a primary mounting plate configured to beattached to the first thermal transfer pad using the second attachingmeans. Moreover, the light assembly includes a second thermal transferpad configured to conduct heat, where the second thermal transfer pad isattachable to the primary mounting plate using the second attachingmeans. Further, the light assembly includes a board configured to beattached to the second thermal transfer pad using the second attachingmeans. Yet further, the light assembly includes an LED Array configuredto generate light, where the LED Array is mounted on the board.Moreover, the light assembly includes a shroud configured to collimatelight generated by the LED Array onto a projector lens comprised in themovie theatre projector, where the shroud is configured to be attachedto the board.

Referring now to the figures, FIG. 1 shows a projector bulb 100 in aprojector used in theatres, according to prior art. The projector bulb100 may include, but is not limited to, High Intensity Discharge (HID)lamp, Xenon lamp, halogen lamp, mercury short-arc lamp, and metal halidelamp.

FIG. 2 shows an exploded view of a light assembly 200 configured to beinstalled in a movie theatre projector, in accordance with variousembodiments disclosed herein. FIG. 3 shows a cross-section view of thelight assembly 200 of FIG. 2, after assembly. FIG. 4 shows a perspectiveview of one end of the light assembly 200 of FIG. 2 installed in a movietheatre projector. The light assembly 200 may be configured to replacethe projector bulb 100, which may an arc discharge lamp and/or anincandescent lamp. The light assembly 200 may include an adaptor 202configured to mechanically couple with a bulb mount 402 of the movietheatre projector. The adaptor 202 may include a cylindrical extension,where an external surface of the cylindrical extension may include screwthreading configured to mate with a complimentary screw threadingcomprised in an internal surface of the bulb mount 402. Further, thelight assembly 200 may include a female socket 204 rigidly connected tothe adaptor 202. The light assembly 200 may also include a male socket206 configured to mate with the female socket 204. Yet further, thelight assembly 200 may include one or more cooling fans 208 configuredto generate airflow. The one or more cooling fans 208 may be attachableto the male socket 206 using a first attaching means. For example, thefirst attaching means may include multiple fan mounting screws 210, asocket adaptor plate 212, socket mounting screws 214 and multiplespacers 216.

Moreover, the light assembly 200 may include a heat sink 218 configuredto dissipate heat. The socket adaptor plate 212 may be disposed betweenthe male socket 206 and the heat sink 218, where the socket adaptorplate 212 may be configured to be attached to each of the male socket206 and the heat sink 218 using the first attaching means. The multiplespacers 216 may be disposed between the socket adaptor plate 212 and theheat sink 218, where the multiple spacers 216 may be configured tomaintain a predetermined distance between the socket adaptor plate 212and the heat sink 218 when the socket adaptor plate 212 may be attachedto the heat sink 218 using the first attaching means.

Further, the heat sink 218 may be attachable to the one or more coolingfans 208 using the first attaching means. Further, the one or morecooling fans 208 may include multiple cooling fans configured to beattached to each other using the first attaching means. Each of the oneor more cooling fans 208 may be configured to be simultaneouslyoperational. Further, one or more cooling fans in the one or morecooling fans 208 may be configured to be activated based on failure ofone or more other cooling fans in the one or more cooling fans 208.Accordingly, the light assembly 200 may also include a failure indicatordevice configured to indicate failure of a cooling fan in the one ormore cooling fans 208.

Further, the light assembly 200 may include a first thermal transfer pad220 configured to conduct heat. The first thermal transfer pad 220 maybe attachable to the heat sink 218 using a second attaching means. Yetfurther, the light assembly 200 may include a primary mounting plate 222configured to be attached to the first thermal transfer pad 220 usingthe second attaching means. The light assembly 200 may include a secondthermal transfer pad 224 configured to conduct heat. The second thermaltransfer pad 224 may be attachable to the primary mounting plate 222using the second attaching means.

Further, the light assembly 200 may include a board 226 configured to beattached to the second thermal transfer pad 224 using the secondattaching means. A Light Emitting Diode (LED) Array 228 may be mountedon the board 226. The LED Array 228 may be configured to generate lightand is composed of a multitude of individual LEDs. For example, thesecond attaching means may include a threaded lamp secure screw 230. Anycombination of the heat sink, cooling fan(s), thermal transfer pads, andthe first and second attaching means may be considered to be part of acooling assembly.

In addition, the light assembly 200 may include a lens mounting plate232 configured to be attached to the primary mounting plate 222 using athird attaching means. The lens mounting plate 232 may be transparent tothe light emitted by the LED Array 228. Multiple lens mount standoffs234 may be configured to maintain a predetermined distance between thelens mounting plate 232 and the primary mounting plate 222 when the lensmounting plate 232 is attached to the primary mounting plate 222.Further, a lens 236 may be disposed over the lens mounting plate 232.The lens 236 may be configured to collimate light emitted from the LEDArray 228. For example, the third attaching means may include one ormore of the multiple lens mount standoffs 234 and multiple lens mountingscrews 238. The third attaching means may be considered to be orconsidered to be part of an attachment assembly.

Further, a lens retainer 240 may be attached to the lens mounting plate232. The lens retainer 240 may secure a placement of the lens 236 on thelens mounting plate 232. The lens retainer 240 may be configured to beattached to the lens mounting plate 232 using a fourth attaching means.For example, the fourth attaching means may include lens retainingscrews 242.

In some embodiments, the adaptor 202 may be configured to receiveelectrical power from the bulb mount 402 when the adaptor ismechanically coupled to the bulb mount 402. Accordingly, in anembodiment, the power available at the bulb mount 402 may be used topower the LED Array 228. Therefore, the light assembly 200 may includeadditional electrical circuitry, such as but not limited to, AC to DCconverter connected to the bulb mount and the LED Array 228. In analternative embodiment, the bulb mount 402 may function as a support formounting the light assembly 200 while LED Array 228 may be poweredeither from a DC power source or the AC power source of the movietheatre projector tapped from another point. In other words, in anembodiment, the adaptor 202 may not be configured to establish anelectrical connection with the bulb mount 402.

In some embodiments, the bulb mount 402 corresponds to an anode or acathode. The conventional bulb (such as, the projector bulb 100 used inthe movie theatre projector, such as an arc discharge lamp or anincandescent lamp includes two terminals that are configured toelectrically connect with an anode terminal and a cathode terminalprovided in the movie theatre projector. Further, the conventionalprojector bulb 100 is configured to be mechanically coupled to each ofthe anode terminal and the cathode terminal. However, the mechanism ofmechanical coupling may differ between the anode terminal and thecathode terminal. In particular, the cathode terminal is configured tobe coupled by a screw-based coupling mechanism while the anode terminalis configured to be coupled by a clip-based coupling mechanism.Accordingly, the light assembly 200 may be provided with the adaptor 202configured to be mechanically coupled with either the anode terminal orthe cathode terminal. Further, in some embodiments, the adaptor 202 maybe configured to couple with both the anode terminal and the cathodeterminal by means of a hybrid coupling mechanism comprised in theadaptor 202 that is configured to mechanically couple with both theanode terminal and the cathode terminal. However, in the case where theadaptor 202 is configured to be mechanically coupled with the anode, aspatial arrangement of the components of the light assembly 200 may besuch that the adaptor 202 does not fall in the path of light exiting thelens 236.

In further embodiments, the light assembly 200 may include an AC-DCconverter configured to convert alternating current to direct current,wherein the AC-DC converter is configured to provide power to the LEDArray 228. According to currently available LED technology, it ispreferable to provide only DC to power the LED Array 228. However, in anembodiment, the LED Array 228 may be such that they may safely operatethrough their life span on AC as well. Accordingly, in an embodiment,the light assembly 200 may not include the AC-DC converter. Further, theLED Array 228 may further be configured to operate directly at thevoltage levels generally provided at the bulb mount 402 of the movieprojector, such as but not limited to, above 1 kV. Yet further, theAC-DC converter may include a power adjuster configured to adjust apower level supplied to the LED Array 228.

Moreover, the AC-DC converter may be electrically connected to theadaptor 202, where the adaptor 202 is configured to receive electricalpower from the bulb mount 402. Accordingly, in an embodiment, althoughthe adaptor 202 may receive electrical power from the bulb mount 402,the AC-DC converter may be situated external to the light assembly 200.Accordingly, the AC-DC converter may not be mechanically attached to thelight assembly 200. Further, the AC-DC converter may be configured to beattached to the light assembly 200 by using a fifth attaching means.Accordingly, in an embodiment, the AC-DC converter may be disposedanywhere in the light assembly 200 and attached using one or more of thefirst attaching means, second attaching means, third attaching means,fourth attaching means and a fifth attaching means. For example, in anembodiment, the AC-DC converter may be disposed on the board 226comprising the LED Array 228. Accordingly, the light assembly 200 maycomprise an electrical path leading from the bulb mount 402 (i.e., oneor more of the cathode terminal and the anode terminal of the movietheatre projector) to the AC-DC converter. In another example, the AC-DCconverter may be mounted on a separate PCB board configured to beattached to any of the modular components of the light assembly 200.Accordingly, the light assembly 200 may further include electrical pathsleading from the bulb mount 402 (i.e., one or more of the anode terminaland the cathode terminal) and to the LED Array 228.

In some embodiments, not all of the components shown in FIGS. 2 and 3are used to form the light assembly. For example, a light assembly mayinclude the adaptor 202 configured to mechanically couple to the bulbmount 402 of the movie theatre projector, the primary LED Emittermounting plate 222 and at least one LED (e.g., LED array 228, SMD-typeLED, COB-type LED, etc.) directly or indirectly attached to the primaryLED Emitter mounting plate 222. The light assembly may also include acooling assembly configured to dissipate heat from the primary LEDEmitter mounting plate 222. The cooling assembly may include a heat sinkconfigured to dissipate heat from the primary LED Emitter mountingplate, a cooling fan configured to generate airflow past the heat sinkand/or one or more thermal pads in contact with the primary LED Emittermounting plate, but not necessarily all of these. The light assembly mayalso include a lens 236 configured to collimate light emitted from theat least one LED. The lens 236 may be attached directly or indirectly tothe primary LED emitter mounting plate 222.

FIG. 5 shows a perspective view of a light assembly 500 configured to beinstalled in movie theatre projector, in accordance with someembodiments. FIG. 6 shows another perspective view of the light assembly500. The light assembly 500 may include an adaptor 502 configured tomechanically couple with a bulb mount 402 of the movie theatreprojector. Further, the light assembly 500 may include one or morecooling fans 504 configured to generate airflow, where the one or morecooling fans 504 may be attachable to the adaptor 502 using a firstattaching means. Further, the light assembly 500 may include a heat sink506 configured to dissipate heat, where the heat sink 506 is attachableto the one or more cooling fans 504 using the first attaching means.

Moreover, the light assembly 500 may include a first thermal transferpad (not shown) configured to conduct heat, where the first thermaltransfer pad is attachable to the heat sink 506 using a second attachingmeans. The light assembly 500 may also include a primary mounting plateconfigured to be attached to the first thermal transfer pad using thesecond attaching means. Further, the light assembly 500 may include asecond thermal transfer pad configured to conduct heat, where the secondthermal transfer pad is attachable to the primary mounting plate usingthe second attaching means.

In addition, the light assembly 500 may include a board 508 configuredto be attached to the second thermal transfer pad using the secondattaching means. The light assembly 500 may also include LED Array 510configured to generate light, where the LED Array 510 is mounted on theboard 508. Further, the light assembly 500 may include a lens mountingplate (not shown) configured to be attached to the primary mountingplate using a third attaching means, where the lens mounting plate istransparent to the light emitted by the LED Array 510. The lightassembly 500 may include multiple lens mount standoffs configured tomaintain a predetermined distance between the lens mounting plate andthe primary mounting plate when the lens mounting plate is attached tothe primary mounting plate. Further, a lens may be configured tocollimate light emitted from the LED Array, where the lens may bedisposed over the lens mounting plate. Yet further, a lens retainer maybe configured to be attached to the lens mounting plate using a fourthattaching means, where attaching the lens retainer to the lens mountingplate secures a placement of the lens on the lens mounting plate.

FIG. 7 shows a perspective view of a light assembly 700 retrofitted in amovie projector, in accordance with some embodiments. The light assembly700 may include an adaptor 702 configured to mechanically couple with abulb mount 704 of the movie projector. Further, the light assembly 700may include one or more cooling fans 706 configured to generate airflow,where the one or more cooling fans 706 may be attachable to the adaptor702 using a first attaching means.

Moreover, the light assembly 700 may include a heat sink 708 configuredto dissipate heat, where the heat sink 708 may be attachable to the oneor more cooling fans 706 using the first attaching means. The lightassembly 700 may also include a first thermal transfer pad configured toconduct heat, where the first thermal transfer pad is attachable to theheat sink 708 using a second attaching means. Further, the lightassembly 700 may include a primary mounting plate configured to beattached to the first thermal transfer pad using the second attachingmeans. Yet further, a second thermal transfer pad may be configured toconduct heat, where the second thermal transfer may be attachable to theprimary mounting plate using the second attaching means.

In addition, the light assembly 700 may also include a board 710configured to be attached to the second thermal transfer pad using thesecond attaching means. Further, the light assembly 700 may include LEDArray configured to generate light, where the LED Array is mounted onthe board 710. Yet further, a shroud 712 configured to collimate lightgenerated by the LED Array onto a projector lens 714 comprised in themovie theatre projector, where the shroud 712 is configured to beattached to the board 710. In an embodiment, the shroud 712 may beconfigured to be attached to the lens mounting plate by a fastener, suchas, but not limited to, screws. Accordingly, the shroud 712 may berigidly attached to the lens mounting plate while being freely movablewith respect to the movie theatre projector lens.

Further, the light assembly 700 may also include an adjustment rod 716configured to adjust an alignment of the light assembly 700 in relationto the projector lens, where a foot portion of the adjustment rod 716 isconfigured to be immovably mounted on a base 718 of the movie theatreprojector, where a head portion of the adjustment rod is movablyattachable to the shroud 712.

Further, the adaptor 702 may be configured to form a tight contact withan interior surface of a projector shroud 720 comprised in the movietheatre projector, where the tight contact directs air flow for cooling,and where the light assembly 700 may be configured to be disposed withinan interior volume of the projector shroud 720.

FIGS. 8A-8B show perspective views of a light assembly retrofitted in amovie theatre projector and including an attachment assembly, inaccordance with some embodiments. FIG. 8A shows an adaptor 802 with anelongated portion 804. Primary mount 806 is attached to lens mount 808,in which lens 810 is disposed over the lens mount 808. The primary mount806 is attached to the lens mount 808 by an attachment assembly thatenables the adjustment of the position of the lens mount 808 withrespect to the primary mount 806. The attachment assembly or a portionof the attachment assembly may be manipulated (e.g., by rotation ortwisting) so as to adjust the distance between the LEDs on the primarymount 806 and a lens aperture involving the lens 810.

For example, the primary mount 806 may be attached to arms 812 thatcontain the lens mount 808. The lens mount 808 is able to move towardsand away from the primary mount 806 while contained within the arms 812.The lens mount 808 may have threaded portions 814 on the outer sides ofthe lens mount 808 that protrude from the lens mount through the gaps inthe arms 812 and are used to guide the lens mount 808 towards and awayfrom the primary mount 806. A collar ring 816 that is threaded on itsinner circumference surrounds the arms 812 and the lens mount 808. Thethreaded portions 814 on the outside of the lens mount 808 engage thethreaded portion on the inside of the collar ring 816. The arms 812, thethreaded portions 814 and/or the collar ring 816 may be considered anattachment assembly for attaching the primary mount 806 to the lensmount 808 in such a way that the distance between them can be adjustedby manipulation of the attachment assembly or at least a portion of theattachment assembly.

When the collar ring 816 is rotated or twisted in one direction, thelens mount 808 travels away from the primary mount 806, such that thedistance between the LED emitters on the primary mount 806 and the lens810 increases. The before and after positions of this manipulation areshown, respectively, by FIGS. 8A and 8B. When the collar ring 816 isrotated in the other direction, the lens mount 808 draws back towardsthe primary mount 806. There may be markings 818 that indicated whatmark the lens mount 808 is to be moved to based on the type ofconventional bulb that is being replaced by the light assembly. Theattachment assembly may also be a “twist-lock” system that locks inplace at each of the settings.

FIGS. 9A-9B show perspective views of a light assembly retrofitted in amovie theatre projector with an adjustable adaptor, in accordance withsome embodiments. FIG. 9B shows the elongated portion 804 of the adaptor802 adjusted to be shorter than the elongated portion 804 shown in FIG.9A. The adjustment may be made by manipulation (e.g., rotation ortwisting) of the adaptor 802, or the elongated portion 804 of theadaptor 802. This adjustment changes the distance between the bulb mount402 and ultimately the primary mount 806. This may also be a twist-locksystem that can be adjusted to markings (e.g., for model “A”, model “B”,etc.) based on the conventional bulb model being replaced. Theseadjustable features provide for in-place sizing of the light assembly(e.g., without changing out attachment assembly parts) that accounts fordifferent sizes of the conventional bulb that is being replaced.

FIG. 10 illustrates a movie theatre projector 1010 in an existing setupwith a HID bulb 1020 that is inserted into bulb mount 1030. Theoperation of the HID bulb 1020 is controlled by an existing controlsystem 1040. In the example setup of FIG. 10, the existing controlsystem 1040 is located on the projector 1010.

According to some embodiments, upon removal of the HID bulb 1020, lightassembly 1110 may be inserted in its place, as shown in the examplesetup of FIG. 11. Similar to the embodiments described above, the lightassembly 1110 includes an adaptor that is configured to mechanicallycouple to the bulb mount 1030. The light assembly 1110 includes a lensand at least one LED directly or indirectly attached to a primary LEDemitter mounting plate. The light assembly 1110 further includes acooling assembly, which may be any combination of a heat sink, a coolingfan and thermal pads.

According to some embodiments, the light assembly 1110 is controlled bya new component, a light assembly control system 1120. The lightassembly control system 1120 may be a standalone system that is externalto the light assembly 1110. Rather than having to reprogram the softwarein the existing control system 1040 and reconfigure the existing controlsystem 1040 and/or the driver of the projector 1010 to account for thedifferent power requirement of the LEDs, the standalone control system1120 is configured to control the operation of the LEDs in the new lightassembly 1110. The standalone control system 1120 may be configured tocontrol a driver for the light assembly 1110 that is separate from anydriver used for the bulb mount 1030 of the projector 1010. Thestandalone system 1120 may also control a cooling fan or any othercomponents of the light assembly 1110.

By connecting the light assembly 1110 to its own control system 1120(and driver), replacement of the HID bulb 1020 will not requireextensive reconfiguration or reprogramming of the projector 1010. Thisis particularly important when different types, brands and models ofprojectors may each have their own software version and powerconfiguration. The solution provided by the embodiments can beconsidered to be platform-independent, especially when the standalonecontrol system 1120 is combined with the adaptor 802 and attachmentassembly 812, 814, 816 described above.

The standalone control system 1120 may have its own accessible on/offcontrols or automatic timing controls. A display and a user entrykeypad, dial or touchscreen may be used to manually control the lightassembly 1110 or to program an automatic timing schedule. The driver forthe light assembly 1110 may utilize the power source of the projector1010 or its own power source. In some embodiments, the movie theatreprojector power output will turn on and off the power to the lightassembly control system 1120 and or the driver of the light assembly1110.

In some cases, the standalone control system 1120 may be configured tocommunicate with the existing control system 1040 directly orindirectly, by a wired or wireless communication link. The communicationmay pertain to when the light assembly 1110 is to be on or off. As aresult, any automatic timing or on/off operations of the projector 1010may continue to be directed from the existing control system 1040 andcarried out by the standalone control system 1120. For example, once thelight assembly 1110 and the standalone control system 1120 areinstalled, an operator of the movie theater projector 1010 may turn theprojector 1010 on and off from the display of the existing controlsystem 1040. The standalone control system 1120 may detect that thelight assembly 1110 should be on or off based on any signals detectedfrom the existing control system 1040.

The power to the driver for the bulb mount 1030 may be disconnected ordisabled upon replacement of the HID bulb 1020. In some cases, signalsfrom the existing control system 1040 that are used to power the bulbmount 1030 may be detected and interpreted by the standalone controlsystem 1120 to turn on or off the light assembly 1110 via the driver forthe light assembly 1110. In other cases, the standalone control system1120 may direct the power from the projector 1010 to the light assembly1110.

According to further embodiments, the setup in FIG. 11 may include asensor 1130, within or near the projector 1010, that provides feedbackto the standalone control system 1120. The sensor 1130 may detect anamount of light emitted from the light assembly 1110. This may be usefulin determining proper illumination by the light assembly 1110 ordetecting any drop in luminance over the life of the LEDs. In someinstances, the sensor 1130 may be located at the movie screen andprovide feedback in wireless signals.

FIG. 12 illustrates another setup, according to some embodiments, wherethe projector 1010 sits in relation to a projector window 1070 and aventilation system 1050 that circulates hot air from within theprojector 1010 through vent 1040. The projector 1010 may also include afan or other ventilation component 1060 that was normally used to passair over the HID bulb 1020. In one example of this new setup, the lightassembly 1110 may include a heat sink and a cooling fan to blow air overthe heat sink. This cooling fan may controlled by the standalone system1120 and may be powered by the same driver used to power the LEDs or aseparate driver. The existing ventilation system 1040, 1050, 1060 mayaid in this heat removal.

However, in another example of the setup of FIG. 12, the light assembly1110 does not include a cooling fan, but only a heat sink. In this case,an air guide 1210 may be used to direct air pushed by ventilationcomponent 1060 over the heat sink. The air guide 1210 may be a funnelwith a hole at the heat sink of the light assembly 1110.

While the light assembly control system 1120 is described as astandalone system in the retrofit embodiments above, in someembodiments, the light assembly control system 1120 is configured tocontrol the projector 1010 and any other operations of the projector1010. The light assembly control system 1120 may be or may be integratedwith the projector control system. This may be the case in new movietheatre projectors that are designed to account for the light assembly1110. Such designs may still call for the light assembly 1110 to beadaptable.

FIGS. 11 and 12 serve to illustrate components for retrofitting a movietheater projector bulb with an LED light assembly, in a manner that isefficient and cost-effective. FIG. 13 shows a flowchart that helps todescribe such a retrofit method 1300, according to some embodiments.Upon removal of the existing bulb (and any unnecessary components thatwould hinder the installation of the light assembly 1110), shown by step1302, the light assembly control system 1120 is placed in or proximateto the projector 1010 (step 1304). The assembly control system 1120 isseparate from the existing control system 1040. This means that theassembly control system 1120, instead of the existing control system1140, is controlling the operation of the LEDs of the light assembly1110. The assembly control system 1120 may be considered separate fromthe existing control system 1040, even if the assembly control system1120 utilizes signals from the existing control system 1040 to determinewhen the light assembly 1110 is to be on or off. The two systems may bephysically separate or placed next to each other for convenience. Theymay share the same power source or the light assembly control system1120 may utilize a separate power source. Here, a power source may be abattery, a power conversion box or a transformer that is capable offitting within the projector.

The light assembly 1110 may be placed in the projector 1010 bymechanically coupling the adaptor of the light assembly 1110 to the bulbmount 1030 of the projector (step 1306). The light assembly 1110 may beelectrically coupled to the light assembly control system 1120 (step1308) so that the light assembly may be controlled and powered. Thelight assembly may be operated solely by the light assembly controlsystem 1120. In some embodiments, a communication link (wired orwireless) is established between the systems (step 1310). This may be alink to simply indicate when the light assembly 1110 is to be on or off.The light assembly control system 1120 may be configured to detectsignals or receive instructions from the existing control system 1040with regard to when the light assembly 1110 is to operate.

There may also be a more extensive exchange of information or signalingbetween the systems when there is a greater level of integration. Thepurpose of the link is to allow for a simpler installation with minimalreconfiguration of the existing projector setup. There may be a softwareupdate to the existing control system and/or a simple adjustment toutilize a communication link between the systems. However, thecomplexity, cooling system management, and particular power requirementsof the LEDs may be left to the new light assembly control system 1120.The method 1300 may also include installation of a sensor (step 1312) toprovide feedback to the light assembly control system 1120. The method1300 of FIG. 13 is just one an example of the retrofit process and theorder of the steps may vary as necessary.

In some cases, an air guide 1210 may be installed to direct air over aheat sink of the light assembly 1110. This may be done whether the lightassembly 1110 has a cooling fan or does not have a cooling fan. Thelight assembly control system 1120 may interface with the ventilationcontrol system, if necessary, directly or through the existing controlsystem 1040.

In various embodiments, the light assembly retrofit may be tailored forno interaction with the existing control system 1040 and projectorcomponents. On the other hand, the light assembly control system may beintegrated with the existing control system 1040 and other projectorcomponents in varying degrees.

According to some embodiments, the light assembly 1110 is configured foreasy replacement of the LEDs (and the cooling fan if there is one). Thiswould involve the scenario where a light assembly has been in operationbut has dimmed slightly below a light or efficiency threshold (likelyundetectable to the customers). Rather than requiring the cost of awhole new light assembly, only the LEDs and cooling fan would need to bereplaced. There is no need to replace the remaining core of theassembly. Therefore, the light assembly 1110 would be constructed suchthat removal of the LED emitter board is facilitated, such as byallowing the lens mount to come off upon twisting the attachmentassembly collar all the way.

FIGS. 14 and 15 shows perspective views of a light assembly that isretrofitted in a movie theatre projector and that includes an attachmentassembly, in accordance with some embodiments. This lighting assembly isconfigured to project a beam in the shape of a square or some otherquadrilateral shape. The shape is generated by the placements of one ormore LEDs on the LED Emitter plate. The LEDs may be part of a COBconfigured to generate the square beam.

The light assembly includes an attachment assembly 1400 that may bemanipulated to adjust the distance between the lens 1410 and the LEDEmitter plate housed within emitter housing 1440, which is attached toand/or includes the cooling assembly.

FIG. 14 shows the attachment assembly 1400 as three tiers, including aprimary adjustor 1420, a secondary adjustor 1430 and the emitter housing1440. The lens 1410 is attached to the primary adjustor 1420, such as atthe top or end of the attachment assembly 1410. The primary adjustor1420 may be cylindrical and hollow, so as to allow light to pass fromthe LED Emitter to the lens 1410. The

The primary mount 806 is attached to the lens mount 808 by an attachmentassembly that enables the adjustment of the position of the lens mount808 with respect to the primary mount 806. The attachment assembly or aportion of the attachment assembly may be manipulated (e.g., by rotationor twisting) so as to adjust the distance between the LEDs on theprimary mount 806 and a lens aperture involving the lens 810.

For example, the primary mount 806 may be attached to arms 812 thatcontain the lens mount 808. The lens mount 808 is able to move towardsand away from the primary mount 806 while contained within the arms 812.The lens mount 808 may have threaded portions 814 on the outer sides ofthe lens mount 808 that protrude from the lens mount through the gaps inthe arms 812 and are used to guide the lens mount 808 towards and awayfrom the primary mount 806. A collar ring 816 that is threaded on itsinner circumference surrounds the arms 812 and the lens mount 808. Thethreaded portions 814 on the outside of the lens mount 808 engage thethreaded portion on the inside of the collar ring 816. The arms 812, thethreaded portions 814 and/or the collar ring 816 may be considered anattachment assembly for attaching the primary mount 806 to the lensmount 808 in such a way that the distance between them can be adjustedby manipulation of the attachment assembly or at least a portion of theattachment assembly.

When the collar ring 816 is rotated or twisted in one direction, thelens mount 808 travels away from the primary mount 806, such that thedistance between the LED emitters on the primary mount 806 and the lens810 increases. The before and after positions of this manipulation areshown, respectively, by FIGS. 8A and 8B. When the collar ring 816 isrotated in the other direction, the lens mount 808 draws back towardsthe primary mount 806. There may be markings 818 that indicated whatmark the lens mount 808 is to be moved to based on the type ofconventional bulb that is being replaced by the light assembly. Theattachment assembly may also be a “twist-lock” system that locks inplace at each of the settings.

In some embodiments, the light assembly may be designed to make the sizeof the projected light footprint on the movie screen adjustable. Thelight assembly can adjust the size or pitch of the beam with a concavelens that moves toward or away from a convex lens by manual adjustment.This feature of the light assembly provides movie projector operators aquick and easy way to account for different distances between theprojector and the screen.

FIG. 14 illustrates a portion of a lighting assembly 1400 that makes thesize of the projected footprint adjustable. The lighting assembly mayinclude an adaptor (not shown) that is configured to mechanically coupleto a bulb mount of the movie theatre projector. Lighting assembly 1400includes an emitter housing 1440 that includes an LED emitter plateinside, with at least one LED directly or indirectly attached to the LEDemitter plate. The LED or LEDs are configured to emit a beam of light. Acooling assembly, as described in earlier embodiments, may be insideand/or attached to emitter housing 1440 in order to dissipate heat fromthe LED emitter plate. To this end, emitter housing 1440 may beperforated or grilled to allow heat to escape.

The LEDs on the LED emitter plate, also referred to as an LED emitter,may be configured to emit light in different shapes, either my LEDplacement on the LED emitter plate or by a light filter. For example,the beam may be quadrilateral in shape to match a screen shape. Thisbeam may be generated by a single square or rectangle LED or by an arrayof LEDs placed to generate a quadrilateral shape. The LEDs may be a partof a COB or other arrangement.

Lighting assembly 1400 may include a lens assembly configured to adjustthe size or pitch of the beam. To enable this adjustment, the lensassembly includes a concave adjustor 1430 with a concave lens inside(not visible in FIG. 14) that is configured to spread the beam emittedfrom the LEDs and a convex adjustor 1420 with a convex lens 1410 that isconfigured to collimate light received from the concave lens. Concaveadjustor 1420 is movably attached to emitter housing 1440 and convexadjustor 1420. The lens assembly 1400 is configured to be manipulated byhand or machine to adjust a distance between the concave lens insideconcave adjustor 1430 and convex lens 1410, thereby adjusting the sizeor pitch of the beam.

FIG. 15 shows that the emitter housing 1440, concave adjustor 1430 andconvex adjustor 1420 of the three-tier lens assembly may be cylindricalin shape and substantially hollow to allow the beam of light emittedfrom the LEDs to pass through and exit lens assembly 1400. As seen inFIGS. 14 and 15, at least part of the inside of convex adjustor 1420 isformed with a screw-like or helix-like pattern in order to allow concaveadjustor 1430 to rotate inside part of convex adjustor 1420. Rotation ofconcave adjustor 1430 moves it up or down within convex adjustor 1420.This attached rotational movement decreases or increases the distancebetween the concave lens and convex lens 1410. This same rotationalattachment exists between the outside of emitter housing 1440 and atleast part of the inside of concave adjustor 1430. The rotation ofconcave adjustor 1430 with respect to emitter housing 1440 can be usedadjust the overall length of the light assembly and/or how the concavelens receives the light emitted from the LEDs. While rotation ortwisting is described here, other designs may use simple straightsliding or other methods of manipulation, internally or externally, maybe used to adjust the lens distances or positions. In some embodiments,one or both of the adjustors may be more permanently attached.

FIGS. 16A-16C show the inside components of the lens assembly, accordingto some embodiments. FIG. 16A shows LED emitter plate 1610 positionedwithin emitter housing 1440. LED emitter plate 1610 emits light beam1640. The “beam” may be formed of light rays that are substantiallyparallel and that hold a shape (e.g., square or rectangular). A beam mayalso include rays of light that are more dispersed. Beam 1640 passesthrough concave lens 1620 in concave adjustor 1430. Concave lens 1620acts to disperse beam 1640 so as to expand its size. The dispersed lightor enlarged beam is received by convex lens 1630 in convex adjustor1420, where convex lens 1630 collimates or shapes beam 1640 to beparallel (or back to being parallel), but now at a different size.

FIG. 16B shows, that by rotation of concave adjustor 1430, the distancebetween concave lens 1620 and convex lens 1630 is reduced, resulting inan emitted beam 1640 that is smaller in size or pitch than in FIG. 16A.FIG. 16C shows a further reduction in the distance, by rotation ofconcave adjustor 1430 and/or convex adjustor 1410. The size or pitch ofemitted beam 1640 is even smaller. Although the change in the distancebetween concave lens 1620 and convex lens 1630 shows a change in thebeam size in the figures, the change in distance between LED emitterplate 1610 and concave lens 1620 may also change the beam. Ultimately,by this new design, the size of emitted beam 1640 can be adjusted tocorrespond to the size of the movie theatre screen and the distance fromthe projector to the screen.

FIGS. 17A-17C illustrate an example of a cooling assembly 1700 withadditional cooling features, according to some embodiments. Similar tothe cooling assemblies shown in FIGS. 3, 5 and 6, FIG. 17A shows acooling assembly 1700 that includes a cooling fan 1702 that passes airover a heat sink 1704. However, in this embodiment, cooling assembly1700 includes a cooling fluid jacket 1706 between heat sink 1704 and theLED emitter plate 1708. Cooling assembly 1700 is configured to runcooling fluid (e.g., refrigerant that will not freeze at lowertemperatures) through jacket 1706 to help bring down the temperature ofLED emitter plate 1708, which is heated by the LEDs 1710.

LEDs 1710 will generate some heat. In some embodiments, LEDs 1710 may bearrayed in a 3-inch square area but use 2,200 W of power. This may be4-5 times the amount of power used for some LED external lighting (e.g.,480 W), where the lighting is provided from a larger surface area thatmay be 10-14 inches wide and 20-26 inches long. LEDs 1710 can producebetween 210,000 and 280,000 lumens of light.

Jacket 1706 and/or LED emitter plate 1708 may be embedded with sensors1712 that pass on temperature information to a control system for thelight assembly (e.g., control system 1120 in FIG. 12), to control theflow of cooling fluid from jacket 1706 to one or more cooling sectionsthrough conduits 1714 (e.g., hoses or pipes). In some cases, sensors1712 will be embedded in jacket 1706 against the portion of LED emitterplate 1708 to which jacket 1706 is attached. Examples of these coolingsections are shown in FIG. 17B. A pump 1716 may move heated coolingfluid from jacket 1706 in the emitter housing of the light assembly tocooling fluid jacket 1718 of a cooling section. Heat is drawn out of thecooling fluid in jacket 1718 using Peltier plates 1720 that are orientedsuch that the cooler side is against jacket 1718. The heat from thehotter side of Peltier plates 1720 transfers to heat sink 1722, which iscooled by additional fans 1724. The cooling fluid is then returned tojacket 1706. FIG. 17C shows a side view of one of the cooling sections.

As mentioned above, Peltier plates may be used in the cooling sections,as opposed to a compressor and dryer or other cooling means. A Peltierplate uses thermoelectric cooling to create a heat flux at the junctionof two different types of materials (Peltier effect). Each of Peltierplates 1720 comprises layers of the different materials to transfer heatfrom one side of the plate to the other, depending on the direction of adirect electrical current supplied to the plate. For clarity, FIG. 17Bdoes not show the electrical wires of Peltier plates 1720 that mayreceive current from the light assembly control system or another powersource.

As shown in FIG. 17B, there could be two or more of these coolingsections that are connected by fluid conduits. These cooling sectionsmay be encapsulated together in some type of foam, while leaving thefans exposed for air movement. The encapsulated cooling sections mayform one unit (with or without legs) that will be mounted just outsideof or near the movie theatre projector. The cooling sections and jacketsmay be constructed of copper, aircraft grade aluminum, or othermaterials with high heat-conductive properties.

Some of these cooling sections may be operating before the heatedcooling fluid is moved from jacket 1706. In this sense, these coolingsections are pre-chilling or super-chilling the portion of the coolingfluid that resides in their respective cooling fluid jackets.

In some embodiments, the cooling fluid coming out of jacket 1706 may bepre-cooled with additional pre-cooler fans. That is, the cooling fluidmay circulate between one fan that pushes air over the cooling fluid andanother fan that pulls the air over the cooling fluid. This may be asecond stage of the cooling, where the first cooling fan 1702 is thefirst stage and the cooling sections are the third stage.

FIGS. 18A-18B illustrate different views of a light assembly that housesthe cooling assembly portion shown in FIG. 17A, according to someembodiments. The cooling sections will be located elsewhere, outside ofthe movie theatre projector. The cooling fluid conduits 1714 that movecooling fluid to and from jacket 1706 can be seen in FIG. 18B.

FIG. 19 illustrates an example internal design of a jacket, such asjacket 1706 or jacket 1718, according to some embodiments. In thisexample, cooling fluid flows in through one hole and towards the centerof jacket 1706. The path then follows a tight circle around the centeruntil the path must sharply turn back in the opposite direction. Thispattern continues until the cooling fluid has passed by as much as thesurface area of LED emitter plate 1708 as possible. The heated coolingfluid will then exit through another hole. In some cases, the patternmay be described as a spiral with multiple turns. The pattern may alsobe a parabolic spiral, such as a modified Fermat, logarithmic orArchimedean spiral. The path is not limited to these patterns and may beany pattern that corresponds to the surface area of jacket 1706.

The cooling sections may not be activated unless sensors 1712 determinethat LED emitter plate 1708 has reached a certain temperature.Previously, cooling fan 1702 and heat sink 1704 may have been the solemeans of dissipating the heat from LED emitter plate 1708. In theseembodiments, cooling fan 1702 and heat sink 1704 may continue to operatewhen the cooling system with the cooling sections are activated. In someembodiments, the cooling assembly control system may activate thepre-cooler fans, described above, as the second stage, before activatingthe fans of the cooling sections, in a third stage. The first, secondand third stages may be activated as necessary, according to thethresholds used by the cooling assembly control system and theinformation from sensors 1712. In some embodiments, various numbers ofthe fans and Peltier plates of the cooling sections may be activated bythe cooling assembly control system, to provide a more incrementalapproach to cooling.

LEDs 1710 may be arrayed in different bulb designs to operate atdifferent power levels. For example, one bulb may use 800 to 1500 W.Another bulb may use up to 3500 W. Another bulb could use up to 7000 W.The higher-powered bulbs would more likely need multiple stages ofcooling.

A more complete lighting assembly with the advanced cooling assemblywill be described. According to some embodiments, a light assembly, suchas shown in FIG. 18A, FIG. 18B and previous figures, may include anadaptor configured to mechanically couple to a bulb mount of the movietheatre projector. The adaptor may be modified as shown in FIGS. 8A to9B. The light assembly may also include an emitter housing, such asshown in FIGS. 18A and 18B, that includes an LED emitter plate and atleast one LED directly or indirectly attached to the LED emitter plateand configured to emit a beam of light. The light assembly may include alens assembly configured to collimate light emitted from the at leastone LED. The lens assembly may include the lens adjustors that are shownin FIGS. 14-16C. The light assembly may further include a coolingassembly configured to dissipate heat from the LED emitter plate, wherethe cooling assembly includes a first cooling fluid jacket coupled tothe LED emitter plate, where the first cooling fluid jacket comprises ametal layer enclosing a hollow path for cooling fluid, and where thefirst cooling fluid jacket is configured to allow the cooling fluid topass into the first cooling fluid jacket, along the path and out of thefirst cooling fluid jacket, thereby drawing heat from the LED emitterplate. The cooling assembly may include a first heat sink coupled to thefirst cooling fluid jacket and a first cooling fan configured to passair over the first heat sink. While a metal layer is described in thisembodiment, the metal layer does not need to be exclusively metal.Furthermore, other non-metal materials may be used for the layer.

The cooling assembly may include one or more cooling fluid conduits andone or more cooling sections configured to receive, via the coolingfluid conduits, the cooling fluid from the first cooling fluid jacket,cool the cooling fluid and return the cooling fluid to the first coolingfluid jacket. Each of the cooling sections may include a second coolingfluid jacket configured to receive and return the cooling fluid, one ormore Peltier plates configured to transfer heat from the second coolingfluid jacket, a second heat sink configured to dissipate heat from thePeltier plates and one or more second cooling fans configured to passair over the second heat sink. The cooling fluid conduits may pass inand out of the emitter housing.

The cooling assembly may include one or more temperature and/othersensors coupled to or embedded within the first cooling fluid jacket,the LED emitter plate and/or the first heat sink. The cooling assemblymay include a cooling control system configured to, based on acomparison of temperature information from the temperature sensors to agiven temperature threshold, activate a pump to move the cooling fluidbetween the first cooling fluid jacket and the cooling sections.

The light assembly may further include pre-cooling fans configured tocool the cooling fluid flowing in the fluid conduits from the firstcooling fluid jacket to the cooling sections. This stage of cooling maybe activated by the cooling control system based on information from thesensors.

As shown in FIG. 19, the path for the cooling fluid in a cooling fluidjacket may include a spiral with multiple turns. In some embodiments,the path may include at least part of an Archimedean spiral, a parabolicspiral, a logarithmic spiral or a Fermat spiral. The pattern of thecooling fluid path may be designed so as to include multiple turns inorder to cover as much surface area as possible.

The cooling assembly may be configured to activate and deactivate thecooling fluid portion of the cooling assembly as necessary, to assistthe cooling fan with moderating the temperature of the LED emitterplate. This may be functionality incorporated into the light assemblycontrol system. This additional cooling may extend the life of the LEDs.The cooling sections utilize cooling fluid jackets and Peltier plates sothat no compressor or dryer is needed for the cooling fluid. The pumpand the fans are the only moving parts of the cooling sections. Thismeans that the cooling assembly requires less maintenance and generatesless noise, while providing an extra level of protection from hightemperatures that may be the result of the movie theatre projector andits surrounding environment. In fact, these cooling sections can besmaller and more effective than other cooling systems used for otherlighting, lasers, etc.

Although the invention has been explained in conjunction with a numberof embodiments, it is evident that many alternatives, modifications andvariations would be or are apparent to those of ordinary skill in theapplicable arts. Accordingly, applicant intends to embrace all suchalternatives, modifications, equivalents and variations that are withinthe spirit and scope of this invention.

1. A light assembly configured to be installed in a projector, the lightassembly comprising: an adaptor configured to mechanically couple to abulb mount of the projector; at least one Light Emitting Diode (LED)emitter; a heat sink configured to dissipate heat from the at least oneLED emitter; a cooling device configured to transfer heat away from theheat sink; a lens mounting unit; and a lens configured to receive andredirect light emitted from the at least one LED emitter, wherein thelens is attached to the lens mounting unit.
 2. The light assembly ofclaim 1, wherein the cooling device is a fan or a liquid circulatingsystem.
 3. The light assembly of claim 1, wherein the cooling devicecomprises one or more elements connected to the heat sink.
 4. The lightassembly of claim 1, wherein the at least one LED emitter is connectedto the heat sink.
 5. The light assembly of claim 1, wherein the lensassembly is configured to collimate light emitted from the at least oneLED emitter.
 6. The light assembly of claim 1, wherein the lens assemblyis configured to adjust at least one of a size and a pitch of the beamof light emitted from the at least one LED emitter.
 7. The lightassembly of claim 1, wherein the adaptor comprises a cylindricalextension.
 8. The light assembly of claim 7, wherein the cylindricalextension comprises screw threading configured to mate with screwthreading of an internal surface of the bulb mount of the projector. 9.The light assembly of claim 1, wherein the adaptor is configured receivepower from the bulb mount when the adaptor is mechanically coupled tothe bulb mount.
 10. A light assembly configured to be installed in aprojector, the light assembly comprising: an adaptor configured tomechanically couple to a bulb mount of the movie theatre projector; anemitter housing that comprises an emitter plate; at least one LEDdirectly or indirectly attached to the emitter plate and configured toemit a beam of light; a lens assembly configured to receive and redirectlight emitted from the at least one LED; and a cooling assemblyconfigured to dissipate heat from the LED emitter plate, wherein thecooling assembly comprises: a heat sink coupled to the emitter plate,wherein the heat sink is configured to draw heat from the LED emitterplate.
 11. The light assembly of claim 10, further comprising a firstcooling device coupled to the heat sink.
 12. The light assembly of claim11, wherein the first cooling device is a fan.
 13. The light assembly ofclaim 10, wherein the heat sink comprises one or more thermal transferpads.
 14. The light assembly of claim 11, wherein the first coolingdevice has one or more cooling elements disposed around a portion of theperiphery of the first cooling device.
 15. The light assembly of claim11, wherein the first cooling device comprises a cooling jacket coupledto the heat sink, and wherein the first cooling device is configured torun cooling fluid through the cooling jacket.
 16. The light assembly ofclaim 15, wherein the first cooling device is located between the heatsink and the emitter plate.
 17. The light assembly of claim 15, furthercomprising one or more sensors that detect temperature information andsend the temperature information to a control system of the lightsystem.
 18. The light assembly of claim 17, wherein the control systemcontrols the flow of fluid through the cooling jacket based upon thetemperature information.
 19. The light system of claim 15, wherein thecooling jacket comprises internal flow path configured to flow thecooling fluid through the flow jacket.
 20. A light assembly configuredto be installed in a projector, the light assembly comprising: anadaptor configured to mechanically couple to a bulb mount of theprojector; at least one Light Emitting Diode (LED) emitter; a coolingdevice configured to dissipate or transfer heat away from the at leastone LED emitter; and a lens configured to receive and redirect lightemitted from the at least one LED emitter, wherein the lens is attachedto a lens mounting unit.